1

Water Audit

Report

Water Audit Report

2016

2

Water Audit

Report

List of Contents

Executive Summary…………………………………………………………………6

About Rantex………………………………………..………………....................7

Water Audit Result………………………………………………………………….16

Water Conservation Practices in Rantex……………………………………...26

Water Conservation Plans………………………………………………………...29

Reference……………………………………………………………………………37

3

Water Audit

Report

List of Figures

Figure 1Rope Dyeing .............................................................................................. 11

Figure 2 Ball Warping .............................................................................................. 11

Figure 3 Sizing ........................................................................................................... 11

Figure 4 Re-Beaming ............................................................................................. 11

Figure 5Stenter ......................................................................................................... 11

Figure 6 Weaving .................................................................................................... 11

Figure 7 Quality Assurance .................................................................................... 11

Figure 8 Final Inspection ........................................................................................ 11

Figure 9 Layout Map of Rantex Pvt. Ltd. ............................................................. 12

Figure 10 Water Turbine and Flow Meters .......................................................... 17

Figure 11 Effluent Treatment Plant ....................................................................... 18

Figure 12 Pictorial Evidence of Wastewater Quality ......................................... 24

Figure 13 Mass Balance Diagram ........................................................................ 25

Figure 14 Pictorial Evidence of ETP Extension Contract ................................... 28

4

Water Audit

Report

List of Graph

Graph 1 Variation in water consumption demand for year 2016 ................. 19

Graph 2 Average Industrial Water consumption demand per month ......... 20

Graph 3 % Industrial Water consumption ........................................................... 21

Graph 4 Average Domestic Water Demand per month ................................ 22

Graph 5 % Domestic Water Consumption Demand ........................................ 22

Graph 6 Avergae Water Demand per month .................................................. 23

Graph 7 % Water Demand Trend ........................................................................ 23

5

Water Audit

Report

List of Table

Table 1 Amount of water withdraw, dischrged and fabric produced for

yaer 2016 .................................................................................................................. 19

Table 2 Water consumption in industrial process .............................................. 20

Table 3 Domestic Wate consumption for the year 2016 ................................. 21

Table 4 Avergae Water Consumption per Month ............................................ 22

Table 5 Leading Water Conservation Practices in Rantex .............................. 28

6

Water Audit

Report

Executive Summary

This report deals with the “Water Audit” of M/S Rantex (Pvt.) Ltd. located at

42 KM Sheikhupura Road, Faisalabad. It was the intention of management

of Rantex Pvt. Ltd. to quantify the amount of water used by their industry.

For said purpose water audit of industry was carried out. Industrial Process

water demand and domestic water demand was determined.

Industry survey was carried out for benchmarking of water consumption

and data collection. Flow meters has properly installed in the industry.

Domestic and industrial water consumption data has been provided for

the year 2016 by the management team of Rantex.

Based on the data & information provided by the management of Rantex

Pvt. Ltd, it is determined through audit that in current scenario domestic

water consumption is 14% and industrial process water consumption is 84%,

and 2% is get lost. Some leading water conservation practices have been

implemented in Rantex in year 2017.

Based on the quantification of water consumption in Rantex Pvt. Ltd.

potential saving has been recommended. Major water saving plans

includes; water conservation in boiler by condensate return system,

installation of rain harvesting system, modification in washing process,

installation of flow fixtures to control flow of water, installation of leakage

detection sensors and some other general recommendations. The impact

of water conservation plan on operational and financial key performance

indicator has also been evaluated.

The above describe task was completed by experts of;

Pak Green Enviro-Engineering Pvt. Ltd.

Pak Green Laboratories (EPA Certified)

46-M, Gulberg III, Lahore, Pakistan

0303-4442335, 042-35441444

Email: pakgreen@hotmail.com

www.pakgreen.pk

7

Water Audit

Report

About RANTEX

8

Water Audit

Report

Rantex Private Limited was formed and incorporated in 1990 to setup a

vertically integrated manufacturing facility to produce and export denim

fabric globally.

The factory is located at 42 KM Sheikhupura Road, Faisalabad which is in

the vicinity of Faisalabad. The covered area of factory is approximately

310,000 square feet.

Rantex Private Limited is capable of manufacturing a diversified range of

Denim Fabric. The management team of Rantex Private Limited comprises

of dedicated and highly motivated individuals, laying much emphasis on

teamwork and interdependency, which brings synergetic results. They

bring with them, experience in the Denim industry, diverse educational

backgrounds, both local and international experience. Rantex Private

Limited has tried to develop a culture where quality is given the top priority,

innovation is encouraged, systems are religiously followed and inspection

procedures are adopted at every stage of production. The amazing fusion

of R&D and PD team leads them to produce denim fabrics ahead of the

trends and produce goods which are “Crafted to Last”

The Product Development Department of Rantex is an efficient force of

highly talented individuals assisting the clients in the reorganization of the

most heard about latest trends which are driven from a comprehensive

study of the most inspirational and influential designers and denim

exhibitions all through the globe.

Rantex with current production capacity of 1.6 million meters a month is a

fast growing company where they aim to reach a mark of 3 million meters

by 2018 for Denim Fabrics.

9

Water Audit

Report

Yet another unique feature at Rantex is the capability of producing Non

Denim Twills, along with Light Weight Denim fabrics with a dedicated

capacity of 2 Million meters a month.

This all has only been possible by strong confidence and entrust from their

customer and they look forward to strengthen their reputation.

With the use of the most modern and advance technology in their

production processes they have very uniquely positioned themselves as

strategic partners to world leading brand labels and with their increasing

capacities they look forward to add more potential partners to their

business portfolio.

Their lean and high efficient supply chain & procurement systems allow

them to deliver outstanding value as well as unbeatable rapid pace to

their customers from purchase order to goods in warehouse.

Key Facts of the Industry:

Name of Industry Rantex Pvt. Ltd

Unit Address 42 KM Sheikhupura Road,

Faisalabad

Total Area 75526 m2

Roof Surface Area 24075 m2

Total Production 1.6 million meter per month

Product Category Jeans

Water Source Turbine 2 Nos.

Capacity: 2 cusecs

Overhead Water Storage Capacity 8000 gallons

Unit Price of water withdraw Rs. 6.5/- per m3

Unit Cost of Raw water treatment Rs. 6.5/- per m3

Unit Price of water treatment Rs. 6.3/- per m3

Water Treatment Plant Capacity 1800 m3 / day

10

Water Audit

Report

Boiler 2 Nos.

Total Staff Strength 975 (Males)

Rantex Private Limited is currently structured around major departments,

which are as follows:

Weaving

Rope Dying

Finishing

Sizing

Inspection

Packing

Mercerizing

PPC

Quality Assurance & Control

Health, Safety & Environmental Department

Human Resource/Administration

Process Flow Diagram:

At Rantex to weave dreams and inspirations of clients into a tangible

reality, raw material is passes through following process. The below process

flow diagram show the detail process detail occurring at Rantex.

Raw Material Ball Warping Dyeing

Weaving Sizing Re-Beaming

Folding Finishing Final Inspection

11

Water Audit

Report

Figure 4 Re-Beaming

Figure 8 Final Inspection

Figure 2 Ball Warping Figure 1Rope Dyeing

Figure 3 Sizing

Figure 6 Weaving Figure 5Stenter

Figure 7 Quality Assurance

12

Water Audit

Report

Figure 9 Layout Map of Rantex Pvt. Ltd.

13

Water Audit

Report

Water Audit of RANTEX

14

Water Audit

Report

Water is one of the most valuable resources and the lifeblood for sustained

economic development of any country. Pakistan, sixth largest country in

the world with a population of 2.48%1 of the world's total population, is

developing with high and medium growth rate of population and industrial

activity respectively.

Hasty urbanization and growing industrial units are showing increasing

trend in water demands. The ground water table is going down due to

unsustainable utilization of water resources. It is reported that 96% of

available water is being used for agriculture, 2% for industrial and the

remaining 2% is used by the domestic sector4

It is reported that industrial water demand in Pakistan will increase two

times from 1.44 Billion Cubic Meter (BCM) in year 2002 to 2.88 BCM by the

year 2025. Ministry of Water and Power (2004) reports that industrial water

demand will increase by 1.6 times from 2.7 BCM in year 2000 to 4.3 BCM in

year 2025. United Nations Development Programme estimates Pakistan’s

current water availability as 1,090 m3 per capita per year.

Textile is the largest industrial sector of Pakistan with respect to production,

export and labor force employment. Pakistan is the 8th largest exporter of

textile products among Asian countries and 12thglobally. The textile industry

is water intensive industry and most of the water is consumed for cleaning

the raw materials, dyeing, washing, printing and various other production

processes. Therefore, water consumption varies among processes,

machine types and setups within a textile mill. In a textile mill, wet

processing that includes pre-treatment, dyeing, and finishing typically

accounts for the majority of water consumption and wastewater

discharge.

For conservation of water resource industries have to quantify their water

demand, after this quantification water conservation plan is applied. The

technique use to quantify the water inputs and out of industry is water

audit.

A water audit (also known as an assessment) is systematic survey of all

water-using fixtures, appliances, equipment, and practices at a facility or

15

Water Audit

Report

campus. A thorough water use audit is the basis of a water use efficiency

improvement plan and sets the foundation for the entire effort.

The purpose of water audit is to:

Benchmarking of water consumption

To identify the water consumption trend

To identify the areas of extensive water consumption

To identify industrial and domestic water consumption per day

To identify un-accounted water e.g. leakages

To develop a complete water balance diagram

To suggest water conservation plan

To evaluate the impact of conservation plan on key performance

indicators

Data Acquisition Plan:

Water audit survey was carried out according to following plan;

Survey Date : 05-June-2017

Starting time : 09: 00 am

Completion time : 05: 00 pm

Survey duration : 8.00 hours

The key components in the water audit methodology undertaken for the

Rantex Pvt. Ltd included;

Pre-Audit Information

Preliminary literature review of concepts and methodologies related to

water audit for industrial processes and domestic usage.

Walk through the entire industry to identify the nature of water uses and

the systems installed in the industry, water supply and discharge system

and process machinery metering system.

Consultation with industry’s administrative person for data and

documentation collection.

16

Water Audit

Report

Conducting Water Audit; Base-lining and Benchmarking

The water audit for Rantex Pvt. Ltd includes data collection for various

identified water uses areas. Water using areas includes domestic usage

and industrial processes. Data collection includes;

Collecting records of water pumped to the overhead tanks, average

bore well withdrawals, to estimate actual supply.

Amount of water entering and exiting each industrial process.

Amount of water use for domestic purposes.

Amount of water entering ETP.

Quality of treated wastewater to be discharged to drain.

Analysis of Audit Results

After conducting above benchmarking and data collection, next phase is

to analyze and representation of results. On the base on these results,

water conservation plans has to be suggest which. All the data is

collecting for the base year of 2016.

All water audit data was represented graphically and in tabular form. And

a water balance diagram was developed which show the detail water

consumption of industry.

17

Water Audit

Report

Water Audit Results:

Water Supply and Water Consumption Pattern:

The main source of water supply is bore well with two turbine of capacity

of 2cusec, one turbine at stand by mood. The water from well is stored into

overhead tank of capacity 8000 gallons. The water is transmitted to whole

industry though overhead tank.

Flow meters has installed for continuous recording and monitoring of

amount of water withdraw.

For proper measurement and monitoring of wastewater, flow meter is

installed at final discharged point in October 2016. Water used in industrial

processes and for domestic purposes is transmitted into effluent treatment

plant after usage. Rantex has effluent treatment plant of capacity 1800m3

per day. After the treatment water is drain into nearby water body.

Wastewater quality after treatment meets the Punjab Environmental

Quality Standards.

Water withdraws record for base year is given in Table 1. Variation in water

consumption demand and fabric production is show graphically and

represented as Graph 1.

Figure 10 Water Turbine and Flow Meters

18

Water Audit

Report

Quantity of Water consumption for industrial process and domestic use was

analyzed from water audit data collection.

Water consuming processes are benchmarked in below process flow

diagram.

Above dashed line areas are water consuming areas. Other than these

benchmarked processes, water is consumed in boiler for production of

steam. In dyeing and sizing water is also used for washing the fabric.

Currently industry has two dyeing machine one is in working mode one for

standby mode.

Raw Material Ball Warping Dyeing

Weaving Sizing Re-Beaming

Folding Finishing Final Inspection

Figure 11 Effluent Treatment Plant

19

Water Audit

Report

Meters are installed on all process machines and on water lines for proper

recording of water being consumed.

Table 1 Amount of water withdraw, dischrged and fabric produced for yaer 2016

Month

Amount of Water

Withdraw per

month m3

Amount of

Water Discharge

per month m3

Fabric

Production in

100 m

Jan-16 49152 - 14451.36

Feb-16 45999 - 13610.25

Mar-16 47795 - 13931.75

Apr-16 44668 - 13344.09

May-16 52285 - 15105.05

Jun-16 50192 - 14859.29

Jul-16 48954 - 14087.35

Aug-16 51769 - 15110.33

Sep-16 53387 - 15935.54

Oct-16 48212 44835 13965.03

Nov-16 37225 33637 10420.14

Dec-16 29896 25753 8503.22

Average 46627 37741 13610

Graph 1 Variation in water consumption demand for year 2016

15000

25000

35000

45000

55000

65000

75000

Fabric Production in hundred meters

Amount of water withdraw in cubic meter

20

Water Audit

Report

In Rantex water demanding industrial processes, huge amount of water

has been used in dyeing process. Table below shows the water demand of

each industrial process. Water demand of water consuming process is also

shown in below given pie-chart.

Table 2 Water consumption in industrial process

Month Dyeing m3 Sizing & Washing

m3

Boiler (Two Boilers)

m3

Water In

Water

Out Water In

Water

Out Water In

Water

Out

Jan-16 24556 24310 8349 8266 6385 2554

Feb-16 22999 22769 7819 7741 5980 2392

Mar-16 23883 23644 8120 8039 6209 2484

Apr-16 22284 22061 7577 7501 5794 2318

May-16 26043 25783 8854 8765 6771 2708

Jun-16 25051 24800 8517 8432 6513 2605

Jul-16 24327 24084 8271 8188 6325 2530

Aug-16 25835 25577 8784 8696 6717 2687

Sep-16 26544 26279 9025 8935 6901 2760

Oct-16 24056 23815 8179 8097 6255 2502

Nov-16 18563 18377 6311 6248 4826 1930

Dec-16 14933 14784 5077 5026 3883 1553

Average 23948.58 23709.10 8084.42 8003.57 6206.08 2482.43

Graph 2 Average Industrial Water consumption demand in m3 per month

Dyeing, 23256.17

Sizing & Washing, 7906.92

Boiler, 6046.58

21

Water Audit

Report

Graph 3 % Industrial Water consumption

Domestic water is consumption includes water used for drinking, washing &

cleaning, in mosque, in washrooms, in kitchen for tea making and for

watering the plant. After the usage water is discharged into ETP for

treatment and after treatment discharged to final drain. Domestic water

demand in Rantex for the year of 2016 is given in below table.

Table 3 Domestic Wate consumption for the year 2016

Month

Water Used in

washrooms ,

cleaning , Masjid,

Mopping m3

Water Used for

watering the

plants m3

Water used in

kitchen for Meal ,

Tea & Drinking

m3

Water used for

construction

m3

Jan-16 3438 2947 2456 982

Feb-16 3220 2760 2300 920

Mar-16 3344 2866 2388 955

Apr-16 3120 2674 2228 891

May-16 3646 3125 2604 1042

Jun-16 3507 3006 2505 1002

Jul-16 3406 2919 2433 973

Aug-16 3617 3100 2583 1033

Sep-16 3716 3185 2654 1062

Oct-16 3368 2887 2406 962

Nov-16 2599 2228 1856 743

Dec-16 2091 1792 1493 597

Average 3256.00 2790.75 2325.50 930.17

Dyeing 63%

Sizing & Washing

21%

Boiler 16%

22

Water Audit

Report

Average amount of water required in different categories of water

consumption is calculated on the basis of provided one year data.

Variation in water demand in different areas of water consumption is

shown in the below graph.

Graph 4 Average Domestic Water Demand in m3 per month

Graph 5 % Domestic Water Consumption Demand

On the basis of water audit result analysis, approximate monthly water

demand of Rantex Pvt Ltd is estimated. Estimated water demand results

are given in below table;

Table 4 Avergae Water Consumption per Month

Water Use Type m3/month

Process Water Demand 37209.00

Domestic Water

Demand 9302

Un-accounted Losses 116.00

Water Used in washrooms ,

cleaning , Masjid,

Mopping m3, 3256.00

Water Used for watering the

plants m3, 2790.75

Water used in kitchen for

Meal , Tea & Drinking m3,

2325.50

Water used for construction m3, 930.17

Water Used in washrooms

, cleaning , Masjid,

Mopping …

Water Used for watering

the plants m3 30%

Water used in kitchen for

Meal , Tea & Drinking m3

25%

Water used for

construction m3 10%

23

Water Audit

Report

Graph 6 Avergae Water Demand in m3 per month

Graph 7 % Water Demand Trend

Water balance diagram for Rantex Pvt Ltd is given below as Figure 9. This

water balance diagram shows the amount of water entering the process

and the amount of water leaving the process. It also represent the amount

of water withdraws in a month along with amount of water treated in ETP in

one month.

Water Consumption tracking Results;

Average Amount of Ground Water Withdraw in a year is 0.548 Million m3.

Average Amount of water used for Industrial Process in a year is 0.446 Million m3.

Average Amount of water used for domestic purposes in a year is 0.100 Million m3.

Total Avg.

Process water

deman…

Total Avg.

Domestic water

deman…

Unaccount

Lossed, 116

Total Avg. Process water

demand per month

79.80%

Total Avg. Domestic

water demand

per month 19.95%

Unaccount Lossed 0.25%

24

Water Audit

Report

After the usage water is discharged to

the effluent treatment plant. Quantity

and quality of effluent is properly

monitored. For quantification of

wastewater flow meters has been

installed. For quality analysis sample has

been analyzed by certified laboratories

periodically. Sample after treatment

meets the Punjab Environmental quality

standards. As this water does not have

any harm full effect on environment so it

is safe to discharge it into nearby water

body. The evidence prove of

wastewater quality is given below;

Figure 12 Pictorial Evidence of Wastewater Quality

25

Water Audit

Report

Figure 13 Mass Balance Diagram

Quantification analysis of wastewater proves that average amount of

wastewater being discharge in a normal day is 1365m3.

The criteria pollutants concentrations are as follow;

pH 7-8

COD <150

BOD <80

TDS <3500

TSS <200

26

Water Audit

Report

Water Conservation Practices in Rantex:

Rantex Pvt Ltd. has implemented many plans for conservation of water

and reduction in water used. Worker awareness training programs are also

organized to make them aware about good house keepings. These

awareness trainings prove very successful for water conservation. Some of

the leading water reduction practices implemented in Rantex Pvt. Ltd are;

Rantex Pvt. Ltd has recently installed Morison Rope Dyeing Machine

to reduce water leakage. Previously installed dyeing machine has

three dryer whereas Morison Rope Dyeing Machine has four dryer

which will reduce water leakage. Target reduction through this

practice is decided up to 5%. Currently Rantex Pvt. Ltd has achieved

2% reduction in water wastage through this practice.

Two chemical dyes EM Soft and Exoline Pad have been replaced by

NPOS and APOS respectively. Formerly used dyes required large

amount of water. This practice is implemented from May 2017.

Target is to reduce water consumption up to 2%. Currently 0.5%

reduction in water consumption is achieved.

During dyeing process Decol chemical is start using for removal of

water hardness since May 2017. This will reduce water consumption

upto 2%. Current achievement through this practice is 0.5%.

For finishing operation, mercerizing machine has been installed since

February 2017. This also proves a leading practice for water

reduction.

For improvement in wastewater quality, Rantex is working on

enhancement of effluent treatment plant capacity. Extension in

existing treatment plant will be done to improve the quality of

wastewater being discharged and also to bear the load. Proposed

plant will have the capacity to treat wastewater flow of 3000m3/day.

Prefeasibility study of proposed treatment plant has also been done

and it proves efficient treatment. Pilot scale study of proposed

treatment shows that after this treatment, wastewater will meet PEQS

27

Water Audit

Report

limits and BSR standards as well. Evidence proof of this operation

improvement is given below;

28

Water Audit

Report

Figure 14 Pictorial Evidence of ETP Extension Contract

Table 5 Leading Water Conservation Practices in Rantex

Leading Practice Target Target achieved

Installation of Morison Rope Dyeing

Machine

5% Reduction in water

leakage 2% reduction

Replacement of dyes chemicals 2% Reduction in water

consumption 0.5% achieved

Removal of water hardness 2% Reduction in water

consumption 0.5% achieved

Installation of Mercerizing Machine N/A N/A

Enhancement in effluent treatment

plant N/A N/A

29

Water Audit

Report

Proposed Water Consumption Reduction Plans:

Water audit techniques was adopted to quantify the amount of water

consumption so that based on these quantifications, an efficient water

management/reduction plan should be developed to improve the overall

industry efficiency. Efficient technique that should be adopted after

auditing is 3R strategy.

Industry is currently is treating its process wastewater onsite and after

treatment it discharge into nearby water body. The treatment plant of

capacity 75 m3/hr is already exists in industry and biochemical treatment of

process wastewater is carried out.

Some amount of withdraw water get losses. These losses include leakage

water through joints, valves and fittings. In current situation water spillage

from machines was observed during audit survey. This spillage was due to

mismanagement in operation.

1. Water Conservation through Rainwater Harvesting System:

Rainwater harvesting means the activity of direct collection of rain water

which can be recharged in to the ground water to prevent fall of ground

water level or storing in surface or underground water tank. It is the most

scientific and cost effective way of recharging the ground water and

reviving the water table. It offers advantage in water quality for both

Plantation and domestic use e.g. flushing toilet and car wash etc. The

ultimate use of this collected water is depending on consumer.

Rainwater harvesting can be carried out by following techniques;

1. Storing rainwater for direct use

2. Recharging ground water aquifer with ground/roof runoff

Direct use of water includes water used for watering green areas, flushing

toilets, Floor cleaning and car washing etc.

Rainwater harvesting system includes on;

Catchment area i.e. the surface area utilized for capturing the

rainwater (roof surface area)

30

Water Audit

Report

Collection device, like tanks or percolation pits used for collecting or

holding the water.

Conveyance system i.e. the system of pipes through which water is

transported from the catchment area to the collection device.

Amount of water that can be harvest is determined by catchment area,

average annual rainfall and co-efficient of rainfall depending upon type

of surface. The roof runoff assessed for designing the harvest structure and

this amount is assessed by following formula.

Runoff = Catchment area * Runoff Coefficient * Rainfall

Runoff = 24075*0.9*628.8

Runoff = 13624m3/yr

However, in practice, this volume can never be achieved since a portion

of the rainwater evaporates from then roof surface and a portion may be

lost to the drainage system. Thus, the net usable or available amount of

rainwater from the roof surface would be approximately 70% to 80% of the

gross volume of rainfall. In the current situation, the actual usable amount

of rainwater would be about 9537m3 to 10899 m3 in a year. This collected

amount of rain water can be used for direct use and it may also be used

for ground water recharge. Both the re-use option has been

recommended.

If this amount of rainwater will be used for recharging the ground

aquifer/bore well, then there will be no financial saving because electricity

charges still has to pay for withdraws of water. But this will sustain our

natural resource of water.

In other words, water will raise the ground water table and increase

availability of water. The estimated cost of installation of system for ground

water recharging is Rs. 1,16,729/- to Rs. 1,71,203/-.

For direct use of rainwater, a storage tank has to be constructed to store

rain water and then this stored water will be transfer for desired used. The

storage tanks can be constructed on surface or below surface.

31

Water Audit

Report

The thumb rule for designing of storage tank is; “build a storage tank of

bottom area equal to the one third area of the roof top and the depth of

the tank equal to three times the average annual rainfall in meter or three

meter whichever is less.” The recommended size of storage tank is

89m×89m×1.88m. Thus the storage capacity of tank will be 14891m3 per

year.

The cost analysis of recommended rainwater harvesting system for direct

use shows that;

Annual saving for water withdraw Rs. 70,843/-

Annual saving for wastewater treatment Rs. 70,843/-

Estimated Installation cost of rainwater

collection system Rs.1,12,060/-

Payback period 1.26 years

Base Year 2018

Target Year 2019

2. Boiler Condensation Return System:

Water is supplied to boiler for steam generation purpose. This steam

produced is direct applied to the manufacturing process for heating

purpose. When steam transfers its heat in a production process or used in

heating a coil or heat exchanger, it converts into liquid phase. This phase

of steam is called condensate.

A huge amount of water can be saved in boiler and steam system through

installing condensate recovery system. This system returns the condensate

after recovery to boiler as feed water with addition of makeup water. As

more condensate will be return, less make up water will be needed. This

will reduce fuel cost, make up water cost, chemical and treatment cost.

A major opportunity for water savings in boiler and steam systems is

through improving the efficiency of condensate water return to the boiler.

As more condensate is returned, less make up water is needed. The reuse

of high purity condensate water reduces the amount of water required.

32

Water Audit

Report

Return of high purity condensate also reduces energy losses due to boiler

blow down. Water use in boiler and steam systems, where temperatures

and pressures vary, is typically accounted for in units of pounds (lbs) per

hour.

When condensate return is implemented or improved and operating hours

are known, the amount of water saved in gallons can be found by

[(condensate load in lbs/hr) x (annual operating hours) / 8.34]

As less or no condensate will be drain so it will reduce treatment cost. Fuel

cost will be reduce as most condensate return will be relatively hot so

reduce the makeup water amount that must be heated. This condensate

is of high purity, this will reduce water treatment cost and also reduce

energy losses in boiler blow down.

Currently Textile industry two boilers of different capacity, produce different

amount of steam. Table below shows the specifications of boilers to be

currently work in Rantex.

Specification Boiler 1 Boiler 2

Capacity 10 10

Fuel Gas/wood Coal

Steam produced 8tons/hr 9tons/hr

Condensate Produced 60% 60%

Pressure 150Psi 150Psi

Feed Water temperature 60°C 60°C

Steam temperature 173°C 173°C

Efficiency 80% 90%

Blow down system Automatic Automatic

Condensate recovery system includes of; condensate recovery vessel,

steam traps and de-aeration tanks. When condensate recovery system is

implemented then amount of water saved can be calculated as;

33

Water Audit

Report

( ) (

)

( ) (

)

Based on data cost analysis of installation of condensate recovery system,

it is found that;

Annual Amount of water saved 39314m3

Annual saving for water withdraw Rs. 2,55,541/-

Annual saving for raw water sTreatment Rs. 2,55,541/-

Annual saving for wastewater Treatment Rs. 2,47,678/-

Estimated Installation cost of condensate

return system

Rs. 3,67,540/-

Payback period 5.8 months

Base Year 2018

Target Year

3. Water Conservation Plan for Washing Process:

Conventional washing systems are based on a single-flow arrangement

and use large amounts of water. Often, products to be rinsed are

immersed completely in fresh water, after which the contents of the tank

are drained. Alternative configuration that is more efficient and effective is

recommended, which is counter current washing system.

In counter-current washing systems, water flows through a series of

connected tanks, in opposite direction to the flow of the product to be

rinsed. Clean water enters at the final wash box and flows counter to the

movement of the fabric through the wash boxes. With this method the

least contaminated water from the final wash is reused for the next-to-last

wash and so on until the water reaches the first wash stage, where it is

finally discharged. There will be only one fresh water feed for entire set of

tanks and it is introduced in the last tank. The effluent of one tank will

34

Water Audit

Report

become feed of preceding tank and so on. So in this way water

consumption of washing process will be reduced.

In current situation, large amount of extracted water is used for washing of

apparels so if this modified process of washing will be adopted in existing

unit then there will be 20-30% reduction in water demand. For one

particular recipe, this technique may be adopted to conserve water with

little investment for modification in existing setup and immediate payback.

It may also require upgrading in the recipes of washing of fabric.

4. Water conservation Plan for Domestic water conservation:

To reduce domestic water consumption of Rantex, it is recommended that

tap should be replace by self-closing taps and tap aerators. These facilities

will reduce water consumption up to 50%.

a. Self-closing taps (Percussion taps/push-down taps)

To deliver flow, the user will push down on the tap head. When the user will

remove their hand, the pressure generated inside forces the tap up and it

will automatically close off the flow (after a delay period set at the time of

installation). A delay period of between 15 and 20 seconds is generally

suitable for hand washing. Water savings up to 50% can be achieved by

this system, but dependent on end flow rate and flo8w duration. Flow rate

of 4-8 liters/min can be achieved by implementation of this facility.

To be most efficient, these taps will need to be well maintained to ensure

correct operation. These taps cost around Rs.6000-8000/- per piece

depending upon the quality and can reduce water use by over 50%,

compared with conventional taps.

b. Tap aerator

In aerator tap the design of the nozzle mixes air with the water under

pressure. When the water exits the nozzle the air expands, increasing the

apparent water flow. Water savings will be typically 50% if fitted with a flow

35

Water Audit

Report

regulator, but dependent on end flow rate. Flow rate can be reduced to

between 2 and 8 liters/minute.

Tap aerators are devices that can be retrofitted to existing taps to mix air

with the water, producing the same force of flow, and cost as little as 400-

500 per unit.

General Recommendations:

The following are some recommendation for the conservation of water in a

particular industry. Although economic benefits of these recommendations

cannot be quantified but these improvements will definitely bring sufficient

reduction in amount of water extracted on daily basis. These are;

A well-designed loss-prevention program should target both real and

apparent losses. Real losses are physical losses including leaks, bursts,

and overflows. Apparent losses are non-physical losses that include

meter inaccuracies and unauthorized consumption, such as theft or

illegal use. Leaks in the supply network may be visible or concealed,

Leakage reduction through detection and repairs can save lot of

water. Use remote sensors for ongoing monitoring of leak detection at

source, transmission, and distribution facilities.

Ensure that meters installed at machines are working properly. Establish

protocol for their proper and regular maintenance, repairing and

calibration. Evaluate and replace older meters.

Reducing excessive pressures in the distribution system can save water

by reducing stresses that could result in leakage, decreasing quantities

of water that are currently leaking, and reducing the amount of flow

through fixtures. Pressure reducing valves should be installed at

appropriate place.

If some maintenance issues were observed visually, immediate response

should be given for its maintenance to eliminate water losses.

Flow fixtures could be installed on the taps on the terraces that are used

for watering the plants. Flow fixtures typically controls, deliver a precise

36

Water Audit

Report

volume of water at faucets, showerheads, and hose outlets, typically

5.6 – 8.3 liters per minute, irrespective of varying line pressure. Other

technology is aerators which are generally installed or taps fitted with

aerators are available, which can cut the water usage of faucets by as

much as 40% from 15 liters per minute to 9.4 liters per minute.

Impact of conservation plan on KPIs:

To check the impact of conservation on resources some key performance

indicators has been identified. Two types of key performance indicators

have been used to assess the performance of water conservation plan.

These indicators are operational and financial key performance indicators.

These indicators will be used as benchmarks to allow management to

track the performance of system and determine the effectiveness of any

improvements made to the water system. It shows the impact of

recommended conservation plan on KPIs of industry. These results exclude

amount of water used for construction purposes.

Impact of Conservation Plan on Key Performance Indicators:

KPI Unit Now Then % Reduction

Operational KPIs

Ground Water Mm3/yr 0.548 0.419 23.5

Domestic Water Mm3/yr 0.100 0.050 50

Process Water Mm3/yr 0.446 0.378 15.2

Wastewater Mm3/yr 0.416 0.318 23.5

Financial KPIs

Water Extraction PKR/yr 3,594,880 2,748,640 -

Raw Water

Treatment PKR/yr 2,899,000 2,457,000 -

Waste Water

Treatment PKR/yr 3,120,740 2,385,000 -

Power Utility PKR/yr 3,087,000 2,583,000 -

37

Water Audit

Report

References

1. Shaikh, M.A., Water conservation in textile industry. Pakistan Textile

Journal, 2009. 2009: p. 48-51.

2. Best Water Management and Cleaner Production Practices for

Industries of Pakistan. Claener Production Institute Draft Report, June,

2013: p. 40-50

3. Barrington, D.J., A. Prior, and G. Ho, The role of water auditing in

achieving water conservation in the process industry. Journal of

Cleaner Production, 2013. 52: p. 356-361.

4. Barrington, D.J. and G. Ho, Towards zero liquid discharge: the use of

water auditing to identify water conservation measures. Journal of

Cleaner Production, 2014. 66: p. 571-576.

5. Water Efficiency in Industrial

Facilityfrom[http://www.afedonline.org/water%20efficiency%20man

ual/PDF/4Chapter%203_Industry.pdf]

6. Water Audit For Centre for Science and Environment (CSE)May,2010

from[www.cseindia.org/userfiles/CSE_water_audit_report.pd]

7. Guidance for Preparing Water Audits and Water Loss Reduction

Plans,Revised May 2013 from

[http://www.mde.state.md.us/programs/Water/WaterConservation/

WaterAuditing/Documents/www.mde.state.md.us/assets/document

/water_cons/Water_Audit_guidance.PDF]

8. Tips, E., & Steam, S. T. E. A. M. Minimize Boiler Blowdown.

9. Sivanappan, R. K. (2006, November). Rain water harvesting,

conservation and management strategies for urban and rural

sectors. In National Seminar on Rainwater Harvesting and Water

Management (Vol. 11, No. 12, p. 1).

10. Tips, E., & Steam, S. T. E. A. M. Return Condensate to the Boiler.

Water Audit

Report